Fuel accessory for fuel tank and method for internally attaching same

ABSTRACT

A fuel tank made of a plastic material and fitted with at least one fuel accessory attached to an inside surface of a wall thereof, wherein the fuel accessory is attached to a predetermined site at the inside surface by fusion welding. Further there is disclosed a fuel accessory for attaching to a site at an inside wall portion of a plastic material fuel tank, comprising a housing formed with an engaging surface attachable to the site. The engaging surface is fitted with a fusion melting element for fusion welding the fuel accessory to the fuel tank.

FIELD OF THE INVENTION

The present invention generally relates to fuel tanks and fuel accessories therefore. More particularly, the invention is directed to a method for attaching a fuel accessory within a fuel tank in a fuel-impermeable manner. The invention is further concerned with fuel accessories suitable for attaching to a fuel tank by such a method.

The term ‘fuel accessory’ as used herein the specification and claims is used to denote any of a variety of devices/fittings commonly attached within fuel tanks (i.e. fuel system components), such as valves of different types (vent valves, roll-over valves, over filling intermitting valves, etc), liquid traps, gauges, filters, etc. and also a seating/carrier attached to the fuel tank and which in turn various valve members are attached thereto.

BACKGROUND OF THE INVENTION

A variety of valves and various other devices are commonly fitted within a vehicle's fuel tank. It is common practice to connect such fuel accessories within a fuel tank by forming an aperture of a size comfortably accommodating the valve's housing, and fixedly attaching the valve by various means, e.g. welding, heat welding, different fasteners, etc.

However, this arrangement has several drawbacks. First, as a consequence of the above arrangement, a portion of the fuel accessories projects from an outside surface of the tank and further, and typically some tubing extends between the fuel accessories which also leis attached to the external surface of the tank.

Second, it is necessary to provide suitable sealing arrangements between the housing and the fuel accessory's housing which often has associated thereto some electric wiring or tubing.

It is thus a growing trend to form as little as possible openings in the tank (ideally only one), and accordingly venting system with its associated valves and connections are relocated as far as possible into the tank.

Another serious consideration concerned with vehicle fuel tanks is the ever-growing requirement of environment concerned organizations and authorities that the rate of fuel permeation from the fuel tank and its associated fuel accessories be minimal. The outcome of this requirement is that new connection means are now required for ensuring essentially permeation-free connection between the fuel accessories and the fuel tank.

Accordingly, it is becoming standard practice to manufacture multi-layered plastic fuel tanks having a substantive low permeation rate to fuel hydrocarbons, and where valves are fitted to such tanks with suitable sealing arrangements or heat welded to an inside wall surface of the tank.

Still another issue concerning connection of valves to vehicle fuel tanks is the effective operation level of the valves, namely the level at which the valve closes (at times referred to as cut-off or shut-off level) and the level at which the valve reopens. One of the considerations governing the operative level is space consuming which is of significant importance in particular in vehicles. It is thus a requirement that the “dead space” i.e. the space between “maximum fuel level” and the top wall of the fuel tank, be reduced to minimum, and care has to be taken not to increase the dead space.

Several patents are concerned with providing a fuel-impermeable attachment of the valve to the fuel tank. For example, U.S. Pat. Nos. 5,404,907, 6,035,883 and 6,289,915 disclose different weldable valve assemblies comprising a valve body extending through an opening formed in the fuel tank, and a weldable connector portion fastened to or integrated with the valve body, for welding onto the outer surface of the polymeric fuel tank.

Another method for attaching valves into a fuel tank is by thermo-forming two mating halves of the tank and pressing the valves and any other fuel accessories are pressed to the tank wall immediately after forming while still partially molten. Then, the two halves of the tank are attached and welded to one another. This method is time consuming and even more so there is a severe risk of leak or permeation through the line of weld of the two tank halves.

A different concept is disclosed in WO Patent Application WO0107806A1 also concerned with minimizing the dead space, wherein there is disclosed a fuel valve comprising a housing entirely received within a fluid tank wherein according to one application, the housing of the valve is formed at an uppermost portion thereof with a stem member for fixedly receiving within a corresponding receptacle formed at a top wall of the tank. According to a second application, the housing of the valve is formed at a top portion thereof with a first connecting member adapted for engagement with a corresponding second connecting member integral with a top wall of the tank, e.g. a snap-type connection.

Still another method for attaching fuel accessories to a fuel tank is disclosed in U.S Patent Application Serial No. US20010013516A1 directed to the so called ‘ship in the bottle’ technique, where during blow molding of the tank one or more valves and other fuel accessories are supported by a support fitting (carrier member), whereby as the tank is formed it integrates with the support fitting by heat welding. This is a complicated and costly procedure.

It is a first object of the present invention to provide a concept for connecting fuel accessories within a fuel tank in a substantially fuel impermeable manner. It is a further object of the invention to provide a fuel tank or a device for attaching to the fuel tank in a substantially fuel impermeable manner, as well as a method for carrying out same.

SUMMARY OF THE INVENTION

According to a first aspect of the invention there is provided a fuel tank made of a plastic material and fitted with at least one fuel accessory attached to an inside surface of a wall thereof, wherein said fuel accessory is attached to a predetermined site at said inside surface by fusion welding facilitated by a fusion melting element extending between the elements. According to a particular embodiment one of the fuel accessory and the site at the inside surface of the fuel tank is fitted with a fusion melting element (at times referred to as a ‘weld insert’), which may be integrated with or added to either of the components.

Fusion welding occurs when the plastic components, i.e. the inside wall site of the fuel tank and a portion of the fuel accessory, both made of a suitable plastic material (e.g. thermoplastic), are attached to one another and the temperature of at least one of the adjoining surfaces is raised above the melting point of the material. Upon cooling thereof, the components remain welded to one another.

According to a second aspect of the invention there is provided a fuel accessory for attaching to a site at an inside wall portion of a plastic material fuel tank, comprising a housing formed with an engaging surface attachable to said site; wherein said at least a portion of the engaging surface is made of plastic material and is fitted with a fusion melting element for fusion welding the fuel accessory to the fuel tank.

According to a third aspect of the present invention there is provided a method for attaching a fuel accessory to a fuel tank made of a plastic material; wherein one of the fuel accessory and a site at the inside surface of the fuel tank is fitted with a fusion melting element and where attaching the fuel accessory is carried out by fusion welding.

According to a fourth aspect of the present invention there is provided a manipulator for introducing and attaching by fusion welding a fuel accessory to a site at an inside wall of fuel tank, said manipulator configured as an arm for introducing into an interior space of the fuel tank through an opening formed in the tank. The manipulator may be for introducing and attaching by fusion welding at least two fuel accessories to a site at an inside wall of a fuel tank. The manipulator may comprise a fuel accessory gripping portion for securely applying a fuel accessory to the wall site and pressurizing it against the wall site during the fusion welding process; the arm being part of a control assembly adapted to control multiple fusion welding attachments of at least two fuel accessories.

According to a further aspect of the present invention there is provided a method for attaching a fuel system component to a fuel tank made of plastic material, the method comprising the following steps:

-   -   (f) providing a fuel system component having at least a housing         portion made of a plastic material, where the housing portion is         pre-fitted with a fusion melting element at a top thereof;     -   (g) providing a manipulator in the form of an arm insertable         into an interior space of the fuel tank through an opening         formed in the tank;     -   (h) introducing the fuel system component into the fuel tank via         the manipulator;     -   (i) positioning the fuel system component at predetermined site         at an inside surface of the fuel tank via the manipulator; and     -   (j) adjoining the top of the housing to said predetermined site         by applying current through the fusion melting element to heat         it to a temperature suitable for melting plastic material and         thereby weld the fuel system component to the fuel tank.

According to yet another aspect of the present invention there is provided a method for simultaneously attaching at least two fuel accessories to a fuel tank made of plastic material, the method comprising the following steps:

-   -   (g) providing at least two fuel accessories, each having at         least a housing portion made of a plastic material, where the         housing portion is pre-fitted with a fusion melting element at a         top thereof;     -   (h) providing a manipulator in the form of an arm insertable         into an interior space of the fuel tank through an opening         formed in the tank;     -   (i) introducing the at least two fuel accessories into the fuel         tank via the manipulator;     -   (j) positioning each of the at least two fuel accessories at         predetermined wall site at an inside surface of the fuel tank;     -   (k) adjoining an engaging surface of each of the tops to said         predetermined wall site; and     -   (l) applying current through the fusion melting elements to heat         them to a temperature suitable for melting plastic material and         thereby simultaneously weld the at least two fuel accessories to         the fuel tank.

According to still a further aspect of the present invention there is provided a method for attachment of a fuel system component to a fuel tank made of plastic material, the method comprising the following steps:

-   -   (h) providing a fuel system component having at least a housing         portion made of a plastic material;     -   (i) providing a weldable carrying member having a fusion melting         element embedded therein;     -   (j) providing a manipulator in the form of an arm insertable         into an interior space of the fuel tank through an opening         formed in the tank;     -   (k) introducing the fuel system component into the fuel tank via         the manipulator;     -   (l) positioning the fuel system component at predetermined wall         site at an inside surface of the fuel tank;     -   (m) disposing the carrying member intermediate the housing of         the fuel system component and the predetermined wall site of the         fuel tank; and     -   (n) adjoining the top portion of the housing to said         predetermined site by heating the fusion melting element and         melting the carrying member to weld at both faces thereof and         form the attachment.

As will be clear from the specification and the drawings a fuel system component in accordance with any of the aspects above may comprise an outlet nozzle adjacent said top of the housing.

The following features may be applicable to any of the above aspects of the invention:

-   -   L) The fusion melting element may be fitted or pre-fitted in         either one of the housing of the fuel accessory or the wall site         of the fuel tank. Alternatively, the fusion melting element may         be separately disposed in-between the housing of the fuel         accessory and the wall site of the fuel tank. It may also be         received within a weldable carrying member, e.g. embedded within         a disc-like member disposed between the housing of the fuel         accessory and the wall site of the fuel tank, whereby heating         the fusion melting element results in melting the carrying         member to weld at both faces thereof and form the attachment.     -   M) The fusion welding element is a filament formed in a coiled         or undulating pattern, possibly embedded within a groove of a         corresponding shape. However, the fusion melting element may         also be in the form of a sheet assuming different shapes, e.g. a         disc-like element, a flat ring element, etc.     -   N) The fusion melting element is activated by an electric         current applied thereto through conductive wires extending from         the fusion melting element. Typically said wires are easily         detachable from the fusion melting element.     -   O) The fusion melting element is activated by an electric         current applied thereto via induction.     -   P) One of the fuel accessory and the site at the fuel tank may         be fitted with a magnetizable member, whereby during the fusion         welding process the fuel accessory is attracted to the site at         the fuel tank by a magnetic force. The inductive current may be         used also for generating the magnetic field for attracting and         engaging the fuel accessory to the wall site and for fusion         welding thereof.     -   Q) The fusion melting element is activated by an electric         current applied thereto through conductive elements engageable         by corresponding current sockets of a fuel accessory applicator.     -   R) The fuel accessory is introduced to the site of the fuel tank         and is supportably retained during the fusion welding process by         a fuel accessory applicator, which according to one embodiment         is in the form of a manipulator configured as an arm for         introducing into an interior space of the fuel tank through an         opening formed in the tank. According to other embodiments, the         manipulator is in the form of device suited for supporting the         fuel accessory and position it against the wall site with         suitable electric supply arrangements, with another portion of         the device suited for bearing against an opposed wall portion of         the fuel tank. Optionally, the manipulator comprises an electric         socket for connecting to a corresponding socket of the fuel         accessory to apply thereby electric current.     -   S) The fuel accessory may be any one or more element of a         variety of such elements fitted within a fuel tank, e.g. valves         of different types (vent valves, roll-over valves, over filling         intermitting valves, etc), fuel traps, gauges, filters, etc. and         also a seating/carrier attached to the fuel tank and which in         turn various valve members are attached thereto.     -   T) A_(t) least a top portion of a housing of the fuel accessory         and the wall site portion of the fuel tank are made of a         suitable plastic material (e.g. Polyethylene—PE) which is heat         weldable, to thereby qualify for fusion welding.     -   U) It is an option that the fuel accessory be engaged with the         wall surface of the tank using a pressure sensing arrangement,         e.g. a strain gage or a micro-switch, to ascertain that the fuel         accessory is tightly and properly engaged with the wall of the         fuel tank.     -   V) A control assembly may be provided for governing several         welding parameters and also for controlling multiple fusion         welding attachments, e.g. simultaneous welding of several fuel         accessories or of a seating/carrier attached to the fuel tank         and which in turn various valve members are attached thereto.

It is thus an object of the present invention to provide a method for attaching a fuel element to a wall site at an inside surface of a fuel tank by fusion welding, and further to provide a fuel accessory and a fuel tank suitable for such attachment, as well as a method for carrying out such attachment, and a devise useful for the method.

While the invention will be described hereinafter in the detailed description with reference to a fuel valve, it will be appreciated that it is not intended to limit the scope of the invention to that embodiment, but rather, to cover all modifications and embodiments as may fall within the scope and the spirit of the invention, and as defined in the claims.

BRIEF DESCRIPTION OF THE DRAWINGS

In order to understand the invention and to see how it may be carried out in practice, several embodiments will now be described, by way of non-limiting examples only, with reference to the accompanying drawings, in which:

FIG. 1A is a side view of a portion of a fuel tank at an area of the tank fitted with a fuel valve, attached thereto by fusion welding;

FIG. 1B is an exploded isometric view of the assembly seen in FIG. 1A;

FIG. 2A is a top isometric view of an embodiment of a fuel valve according to the present invention;

FIG. 2B is a longitudinal section through the fuel valve and the wall site seen in FIG. 1A;

FIGS. 3A and 3B are top isometric views of fuel valves according to other embodiments of the invention;

FIG. 4 is a schematic sectional side view of a portion of a fuel tank during fusion welding thereto of a fuel valve according to an embodiment of the invention;

FIG. 5A is a schematic sectioned side view of a portion of a fuel tank with a fuel valve attached thereto, according to another embodiment of the invention;

FIG. 5B is an exploded sectional side view of the assembly of FIG. 5A;

FIGS. 6A to 6D are schematic representations of fusion welding process according to different embodiment of the present invention;

FIG. 7 illustrates a modifications of the present invention, wherein engagement pressure control arrangements are provided; and

FIG. 8 is a schematic representation illustrating simultaneous assembly of two valves within a fuel tank.

DETAILED DESCRIPTION OF THE INVENTION

Attention is first directed to FIG. 1A illustrating a top wall portion 10 of a fuel tank (not seen in whole) made of a thermoplastic material with a fuel accessory, namely roll-over valve generally designated 20 attached thereto at a wall site designated 22.

Hereinafter in the drawings and description, reference will be made to a fuel accessory which is in the form of a valve though, one should appreciate that the term fuel accessory should be understood in its broadest meaning, referring to, among others, different types of valves, liquid traps, gauges, filters etc., as well as carriers attached to the fuel tank and which in turn bear valve members etc.

In the present Examples, the fuel accessory 20, is a roll-over valve comprising a housing 24 made of a thermoplastic material and a snap-type closure member 28 retaining in place the valve's components.

It is further noticed in FIG. 1A that no connecting means are required for attaching the valve to the fuel tank's wall portion 10, whereby the effective dead space, namely the space between maximum fuel level and the top wall of the tank is retained to a minimum and further whereby the outlet nozzle 30 extends right adjacent below the bottom surface 32 of the top wall 10 of the fuel tank. However it is noted that no apertures are formed at the fuel tank's walls and thus fuel vapor is retained to a minimum.

As already mentioned, the valve 20 is attached to the fuel tank's top wall 10 by fusion welding, facilitated by a coiled fusion melting element 36, which in the particular illustrated embodiments is accommodated within a corresponding coiled path 38 formed at a top engaging surface 40 of the valve 20.

It is noticed that the top engaging surface 40 has a contour corresponding with that of the wall site which, in the present case, is flat, so as to ensure adequate contact surface.

It is further noticed in FIGS. 1B and 2A that the coiled fusion melting element 36 has two conductive leg members 42A and 42B, respectively, for applying to the coiled filament an electric current. The housing 24 of valve 20 is fitted at an upper portion thereof with grooves 44A and 44B, through which the conductive legs project, whereby the conductive leg portions may then be engaged by conductive wires or other conductive means as will be discussed hereinafter.

According to another alternative (not shown), the fusion melting element may also be received within a weldable carrying member, e.g. embedded within a disc-like member disposed between the housing of the fuel accessory and the wall site of the fuel tank, whereby heating the fusion melting element results in melting the carrying member to weld at both faces thereof and form the attachment.

In FIG. 3A there is illustrated a valve generally designated 50 wherein the fusion melting element 52 is in the form of an undulating filament received within a corresponding groove 54 formed at a top wall portion of the valve housing 56, with conductive leg portions 58A and 58B extending through corresponding grooves 60A and 60B formed along a portion of the housing 56 and extending to electric sockets 62A and 62B, respectively, for engagement with a current applicator, as will be explained hereinafter with reference to FIG. 6A.

FIG. 3B is directed to a valve 50′ similar to that disclosed in connection with FIG. 3A above, with the exception that the fusion melting element 63 is in the form of an open rink-like sheet of conductive material extending along foundries of the housing, and engageable with a current supply source via legs 64 projecting through a peripheral portion 65 of the housing. It is however appreciate that other shapes of a fusion melting element are possible also at sheet form.

It is further noticed that the housing (24 in FIGS. 1 and 2A and 56 in FIG. 3) is fitted with a annular projecting shoulder 70, the purpose of which will become apparent hereinafter with reference to FIGS. 6A and 6B.

In the illustration of FIG. 2B it can be seen how the valve 20 is welded at the wall site 22 of the bottom surface 32 of a top wall 10 of a fuel tank by fusion welding at 66. Fusion welding is carried out by applying an electric current through the fusion melting element, namely metal coil 36 to thereby heat the thermoplastic material to a temperature above its melting point whilst retaining the valve 20 against the surface 32 and allowing the molten material to cool down, whereby welding is obtained.

Different parameters govern the fusion welding process, e.g. thickness and intensity of the filament of the fusion melting element, pattern and intensity of the coils or undulants, depth of accommodating groove within the respective element, type of plastic material, size of weldable portion, and the magnitude of the electric current applied through the fusion melting element. Furthermore, depending on the shape and size of the fuel accessory, one or more fusion welding focuses may be applied, i.e. in case of a large carrier member, several welding sites may be performed.

Further attention is now directed to FIG. 4 in which there is illustrated an embodiment of fuel valve 76 in accordance with another embodiment, fitted at a top portion of the housing 78 with a coiled fusion melting element 80 and below there is provided a metallic member 82 (a disc in the represent example) embedded within the top portion of the housing 78. The arrangement is such that during the fusion welding process electric current to the fusion melting element 80 is excited by induction applied via an inductive coil member 86, generating also a magnetic force acting on the disc 82, so as to attract the entire housing 78 into tight engagement with the bottom surface 90 of the top wall portion 92 of the fuel tank.

In accordance with a modification of this embodiment (not shown), the disc 82 is not embedded within the housing 78 of the fuel accessory but is rather fitted within the space 96 of the valve and may then be removed after completing the fusion welding process.

The embodiment illustrated in FIGS. 5A and 5B differs from the previous embodiments in the general configuration of the fuel accessory, i.e. valve 100, and further the top wall portion 102 of the fuel tank is formed with a protruding valve receiving formation 104 fitted for snugly receiving a top portion of the housing of valve 100, thereby making it unnecessary to support the valve during the welding process.

In this embodiment, the fusion melting element is a coiled filament 106 coaxially extending about the top portion 108 of the housing of the valve 100. Optionally, the top portion 108 is formed with a corresponding coiled path (not shown) for receiving the fusion melting element 106.

The arrangement disclosed in FIGS. 5A and 5B ensures a minimal dead space between the bottom surface 110 of the top wall 102 of the fuel tank and the maximum fuel level within the valve 100.

FIG. 6A illustrates a process for fusion welding of a fuel accessory designated 140 to a bottom surface 142 of a top wall portion 144 of a fuel tank, using a manipulator 148.

The fuel accessory 140 corresponds with the valve 20 of FIGS. 1B and 2A and comprises a housing 148 formed with an annular shoulder 150 and a coiled path 154 receiving a coiled fusion melting element 156 with its conductive legs 158A and 158B laterally projecting through grooves 160A and 160B formed at a top portion of housing 148.

During the fusion welding process, the valve 140 is placed within a receptacle 166 of a fuel accessory applicator 168 of manipulator 148.

In operation, the manipulator arm is introduced through an opening formed in the fuel tank (typically a fuel pump aperture formed in the tank or any other suitable such opening) with the valve 140 received within the receptacle 166 with the annular shoulder 150 bearing against the top surface 170 of the applicator and whilst the conductive leg portions 158A and 158B engage electric sockets 172A and 172B of the manipulator 148, in turn connected by suitable conductive wires 176A and 176B, respectively, to a power supply 180.

Upon applying the top surface of the valve housing 148 to the bottom surface 142 of the top wall 144 of the fuel tank, an electric current is applied through sockets 172A and 172B to conductive legs 158A and 158B, respectively, of the fusion melting element 156, whereby heat is generated at the coil, until the plastic material melts. Then, the current ceases to allow cooling down of the molten plastic material, whereby fusion welding is obtained.

In the embodiment of FIG. 6B, the manipulator 186 is similar to that seen in FIG. 6A with the exception that it is not used to apply an electric current, but rather to position the valve 188 at the appropriate wall site of the top wall 190 of the fuel tank and apply moderate pressure during the fusion welding process. However, in this particular example, the fusion melting element 194 is heated by a current applied thereto via induction, applied by an external induction coil 198.

In both the embodiments of FIGS. 6A and 6B, the manipulator 148 and 186, respectively, is removed after cooling down of the fusion welded zone.

Turning now to FIG. 6C there is illustrated a fuel valve generally designated at 200, fitted with a fusion welding element 202, as disclosed according to any of the embodiments according to the invention. In order to correctly position the valve 200 at the welding site and to ensure proper surface contact with the inner wall surface 204 of the fuel tank, a piston assembly 210 is provided, wherein one end thereof 212 bears against a bottom wall 214 of the fuel tank and an upper retractable member thereof 216 is fitted with a valve receptacle 218 and appropriate current conducting means (not shown). The arrangement is such that the upper member 216 is spring biased by a coiled spring 220, so as to apply axial force to the valve 200, so that during the welding process it properly engages the inner wall surface 204 of the tank. The piston assembly may be operated by different means such as, for example, electromagnet, hydraulic, pneumatic, etc.

In the embodiment of FIG. 6D the valve 220 with the associated fusion welding element 222 are received within a receptacle 224 of a extendable ‘scissors type’ mechanism 228, wherein one leg portion has a support member 230 bearing against a bottom wall portion 232 of the fuel tank and whereby retracting the leg portions of the mechanism entails vertical displacement of the receptacle 224 for positioning the valve 220 flush against an inner wall surface 236 of the fuel tank, whilst applying suitable force, whereby applying an electric current to the fusion welding element entails fusion welding, as discussed hereinabove.

Further reference is now directed to FIG. 7. In order to ascertain that during the fusion welding process the fuel accessory, e.g. a valve 240, is properly and tightly engaged with a corresponding wall portion 242 of the fuel tank, there may be provided pressure indicators 246 e.g. in the form of strain gages or micro-switches, which in the present embodiment are mounted on the end of the manipulating arm 250. Such pressure indicating means or sensors may however be mounted at other locations thereof.

The illustration of FIG. 8 exemplifies how two fuel accessories, namely valves 260A and 260B are simultaneously fitted to an inner wall surface 264 of a fuel tank. The arrangement is such that two inductive coil members 266A and 266B are positioned in register with the welding location of the corresponding valves 260A and 260B, and further there is provided a controller C for simultaneously applying current to the inductive coil members 266A and 266B and the valves 260A and 260B. It is appreciated that this arrangement is suitable also for a large fuel accessory (rather then separate valves0, e.g. in the case of a carrier member attached to the fuel tank's inner wall, with respective fuel accessories attached in turn to said carrier.

Whilst several embodiments have been shown and described, it is to be understood that it is not intended thereby to limit the disclosure, but rather it is intended to cover all embodiments, modifications and arrangements falling within the spirit and the scope of the present invention, as defined in the appended claims, mutatis mutandis.

For example, the fusion melting element may be integrated a priori within one of the fuel element or the wall site of the fuel tank or, it may be introduced into a suitable receptacle formed in either of the fuel accessory or wall site. In accordance with a different alternative, the fusion melting element is merely introduced between the fuel accessory and the wall site. 

1-50. (canceled)
 51. A method for attaching a fuel system component to a fuel tank made of plastic material, the method comprising the following steps: (a) providing a fuel system component having at least a housing portion made of a plastic material, where the housing portion is pre-fitted with a fusion melting element at a top thereof; (b) providing a manipulator in the form of an arm insertable into an interior space of the fuel tank through an opening formed in the tank; (c) introducing the fuel system component into the fuel tank via the manipulator; (d) positioning the fuel system component at predetermined site at an inside surface of the fuel tank via the manipulator; and (e) adjoining the top of the housing to said predetermined site by applying current through the fusion melting element to heat it to a temperature suitable for melting plastic material and thereby weld the fuel system component to the fuel tank.
 52. A method according to claim 51, wherein the fusion melting element is heated by current applied thereto through detachable conductive wires.
 53. A method according to claim 51, wherein the fusion melting element is heated by current applied thereto by induction.
 54. A method according to claim 51, wherein the fusion melting element is heated by current applied thereto through an electric socket of the manipulator.
 55. A method according to claim 51, wherein the housing of the fuel system component is fitted with a magnetizable member for attraction to a wall site at the fuel tank during the fusion welding process.
 56. A method according to claim 51, wherein fusion welding is excited by an inductive current generating a magnetic field for attracting and engaging the fuel system component to a wall site within the fuel tank by a magnetizable member fitted within one of the fuel system component and a wall site at the fuel tank.
 57. A method according to claim 51, wherein electric current is applied to the fusion melting element via an electric socket of the manipulator, engageable with a corresponding socket member of the fuel system component.
 58. A method according to claim 51, wherein the fuel system component is a valve.
 59. A method according to claim 51, wherein the fuel system component comprises an outlet nozzle adjacent said top of the housing.
 60. A method according to claim 51, wherein the fuel system component is engaged with the wall surface of the tank using a pressure sensing arrangement.
 61. A method according to claim 60, wherein the pressure sensing arrangement is selected from the group including a strain gage and a micro-switch.
 62. A method according to claim 51, wherein the fuel system component is engaged with the wall site of the fuel tank by a manipulator bearing at one end against a bottom wall portion of the fuel tank extending opposite the wall site of the upper wall portion, and an other end thereof supporting the fuel system component and biasing it against the wall site.
 63. A method according to claim 51, further including steps of providing at least one additional fuel system component, and adjoining the additional fuel system component to the fuel tank simultaneously with said fuel system component.
 64. A method for simultaneously attaching at least two fuel accessories to a fuel tank made of plastic material, the method comprising the following steps: (a) providing at least two fuel accessories, each having at least a housing portion made of a plastic material, where the housing portion is pre-fitted with a fusion melting element at a top thereof; (b) providing a manipulator in the form of an arm insertable into an interior space of the fuel tank through an opening formed in the tank; (c) introducing the at least two fuel accessories into the fuel tank via the manipulator; (d) positioning each of the at least two fuel accessories at predetermined wall site at an inside surface of the fuel tank; (e) adjoining an engaging surface of each of the tops to said predetermined wall site; and (f) applying current through the fusion melting elements to heat them to a temperature suitable for melting plastic material and thereby simultaneously weld the at least two fuel accessories to the fuel tank.
 65. A method for attachment of a fuel system component to a fuel tank made of plastic material, the method comprising the following steps: (a) providing a fuel system component having at least a housing portion made of a plastic material; (b) providing a weldable carrying member having a fusion melting element embedded therein; (c) providing a manipulator in the form of an arm insertable into an interior space of the fuel tank through an opening formed in the tank; (d) introducing the fuel system component into the fuel tank via the manipulator; (e) positioning the fuel system component at predetermined wall site at an inside surface of the fuel tank; (f) disposing the carrying member intermediate the housing of the fuel system component and the predetermined wall site of the fuel tank; and (g) adjoining the top portion of the housing to said predetermined site by heating the fusion melting element and melting the carrying member to weld at both faces thereof and form the attachment.
 66. A manipulator for introducing and attaching by fusion welding at least two fuel accessories to a site at an inside wall of a fuel tank, said manipulator configured as an arm for introducing into an interior space of the fuel tank through an opening formed in the tank, and comprising a fuel accessory gripping portion for securely applying a fuel accessory to the wall site and pressurizing it against the wall site during the fusion welding process; the arm being part of a control assembly adapted to control multiple fusion welding attachments of at least two fuel accessories.
 67. A manipulator according to claim 66, comprising an electric socket for connecting to a corresponding socket of at least one of the at least two fuel accessories to apply thereby electric current.
 68. A manipulator according to claim 66, wherein pressure sensitive arrangements are provided to ascertain that the fuel accessory is tightly and properly engaged with the wall of the fuel tank.
 69. A manipulator according to claim 68, wherein the pressure sensitive arrangements are selected from the group including a strain gage and a micro-switch.
 70. A manipulator according to claim 66, wherein a pressure sensitive arrangement is provided for determining correct application of the fuel accessory to the wall site and confirming correct pressure application of the fuel accessory against the wall site during the fusion welding process. 